Apparatus and method for pre-shrinking a wet fabric prior to drying

ABSTRACT

An apparatus and method for pre-shrinking a wet fabric prior to drying. The apparatus includes, among other components, a balloon extractor station and a hydro-sizer compression station. The balloon extractor station removes some water from the wet fabric. The hydro-sizer compression station is operatively connected to, and disposed downstream of, the balloon extractor station, and compresses the wet fabric in a lengthwise direction, and in so doing, pre-shrinks the wet fabric prior to drying. The method includes, among other steps, extracting some water from the wet fabric so as to form a hydro-extracted and wet fabric, compressing lengthwise the hydro-extracted and wet fabric so as to form a compacted and wet fabric that is now pre-shrunk prior to drying, and drying the compacted and wet fabric so as to form a compacted and dry fabric.

CROSS REFERENCE TO RELATED APPLICATIONS

The instant non-provisional patent application is a divisional patentapplication Ser. No. 14/994,278, filed on Jan. 13, 216, for APPARATUSAND METHOD FOR PRE-SHRINKING A WET FABRIC PRIOR TO DRYING, which claimspriority from provisional patent application No. 62/283,862, filed onSep. 11, 2015, for PRE-SHRINKING OF FABRIC IN WET CONDITION, and the twoincorporated herein in their entirety by reference thereto.

BACKGROUND OF THE INVENTION Field of the Invention

The embodiments of the present invention relate to an apparatus andmethod for shrinking a fabric, and more particularly, the embodiments ofthe present invention relate to an apparatus and method forpre-shrinking a wet fabric prior to drying.

Description of the Prior Art

Garment producers and other manufactures are continuously trying tolower acceptable standards of shrinkage in 100% cotton andcotton/synthetic blended fabrics and apparel. Typically, a finishedfabric standard of not more than −5% length x −3% width is allowable,and further typically, finished garment shrinkage standards usually arenot more than −8% length x −8% width.

These results can be obtained with proper knitting and finishingprocesses. Now, the standards for garments and apparel are being loweredto −3% to −4% length shrinkage x −3% to −4% width shrinkage by severalmajor U.S. producers.

Fabric producers are unable to obtain the finished fabric shrinkageresults to meet these standards without chemical fixation, through theuse of resins. Many resins are, however, objectionable from a cost standpoint, as well as health concerns because certain resins have been shownto produce cancer. Further, mechanical compaction of the fabric reducesthe lengthwise shrinkage of the fabric without chemicals, but the newstandards cannot be met by the prior art.

Numerous innovations for compressively treating fabrics have beenprovided in the prior art, which will be described below inchronological order to show advancement in the art, and which areincorporated herein in their entirety by reference thereto. Even thoughthese innovations may be suitable for the specific individual purposesto which they address, nevertheless, they differ from the embodiments ofthe present invention in that they do not teach an apparatus and methodfor pre-shrinking a wet fabric prior to drying. For example:

U.S. Pat. No. 3,015,145 to Cohn et al.

U.S. Pat. No. 3,015,145—issued to Cohn et al. on Jan. 2, 1962 in U.S.class 26 and subclass 18.6—teaches a method of compressively treatingfibrous web material, which includes the steps of feeding the materialin a positive manner and at a first predetermined uniform speedsubstantially to an entry line of a treating zone by closely confiningboth principle surfaces of the material to a predetermined path duringthe feeding, discontinuing the positive feeding and the close confiningsubstantially at the entry line, retarding the material to a secondpredetermined uniform speed at an exit line of the treating zone,whereby the material is caused to decelerate and decreases in length andthereby increases in thickness in passage through the zone, andsubjecting the material to heat and substantial localized pressure atthe exit line of the treating zone. The increased thickness of thematerial is substantially greater than that of the predetermined path,whereby decelerating portions of the fabric are confined substantiallyto the treating zone. The predetermined path is of a length severaltimes larger than the length of the treating zone.

U.S. Pat. No. 4,562,627 to Milligan

U.S. Pat. No. 4,562,627—issued to Milligan on Jan. 7, 1986 in U.S. class26 and subclass 18.5—teaches a process for finish drying of tubularknitted fabrics from a wet condition to a substantially finished form ina single process. Wet treated and mechanically extracted fabric issignificantly overspread laterally as it enters the upstream end of thedryer, and although already wet, the fabric is steamed. Thereafter, andthroughout most of its travel through the dryer system, the fabric ishandled to avoid stitch tension to the greatest possible extent, whilethe wet fabric is assuming geometric stability. The discharged fabric isvirtually finished and ready for the cutting table. Mechanical rollercompacting of fabrics in a wet condition enables the wet-compactedfabric to be dried to a substantially finished condition withoutsignificant loss of its compacting.

U.S. Pat. No. 4,882,819 to Milligan et al.

U.S. Pat. No. 4,882,819—issued to Milligan et al. on Nov. 28, 1989 inU.S. class 26 and subclass 18.6—teaches a method for compressivelengthwise shrinking of tubular knitted fabrics and other materials,particularly, in a single stage. Feeding and retarding rollers areseparated from each other by a distance significantly greater than thethickness of the fabric. Zone-forming blades are projected between therollers from opposite sides and form therebetween a confinement zonethat extends at a large angle from the feeding roller to the retardingroller. Fabric is guided to the zone under low contact pressure by thefeeding roller and is conveyed away from the zone under similarly lowcontact pressure by the retarding roller. At the entrance to the zone,the fabric is decelerated and compacted lengthwise without burnishing orabrasion and without crimping. Tubular and open width knitted fabricscan be compressively pre-shrunk in large amounts up to 25% and more in asingle stage.

U.S. Pat. No. 5,016,329 to Milligan et al.

U.S. Pat. No. 5,016,329—issued to Milligan et al. on May 21, 1991 inU.S. class 26 and subclass 18.5—teaches an apparatus for compressivelengthwise shrinking of tubular knitted fabrics and other materials,particularly, in a single stage. Feeding and retarding rollers areseparated from each other by a distance significantly greater than thethickness of the fabric. Zone-forming blades are projected between therollers from opposite sides and form therebetween a confinement zonethat extends at a large angle from the feeding roller to the retardingroller. Fabric is guided to the zone under low contact pressure by thefeeding roller and is conveyed away from the zone under similarly lowcontact pressure by the retarding roller. At the entrance to the zone,the fabric is decelerated and compacted lengthwise without burnishing orabrasion and without crimping. Tubular and open width knitted fabricscan be compressively pre-shrunk in large amounts up to 25% and more in asingle stage.

U.S. Pat. No. 6,047,483 to Allison et al.

U.S. Pat. No. 6,047,483—issued to Allison et al. on Apr. 11, 2000 inU.S. class 34 and subclass 128—teaches a heating system for a mechanicalcompressive shrinkage apparatus in which a continuously flowing liquidheat-exchange medium is caused to flow in series through each of thecomponents required to be heated. Heat is inputted to the flowing mediumin accordance with the temperature of one of the components to beheated, preferably, the first in the series. Uniformity and constancy ofboth absolute and relative temperatures of the series-connectedcomponents is achieved. A mixture of water and propylene glycol alcoholis the heat-exchange medium that allows operation at lower pressurewithout the maintenance problems of a system using, for example, oil asthe exchange medium.

U.S. Pat. No. 6,681,461 B1 to Catallo

U.S. Pat. No. 6,681,461 B1—issued to Catallo on Jan. 27, 2004 in U.S.class 26 and subclass 18.6—teaches a method and apparatus forshrink-proofing a fabric, typically, a knitted textile composed ofinterlocked loops of yarn made of at least one of natural and man-madefibers. The loops interlock along stitch rows that may become skewed.The fabric is confined from expanding as it is delivered to, anddischarged from, an in-line compression zone free of obstructions, suchas, one of crimps, bends, and kinks. The fabric is confined, preferably,resiliently coming to, passing through, and leaving, the compressionzone so as to accommodate variations of thickness and irregularities ofthe fabric being compacted in the compression zone. The interlockedloops are organized, whereby they are allowed to move toward each otherorthogonally along their related stitch row so as to reduce volume ofthe fabric. Non-woven textiles, papers, papers with additives, and thelike are shrink-proofed in the same manner.

U.S. Pat. No. 8,590,122 B2 to West et al.

U.S. Pat. No. 8,590,122 B2—issued to West et al. on Nov. 26, 2013 inU.S. class 26 and subclass 18.6—teaches a two-stage process andapparatus for compacting tubular knitted fabrics. At each stage, thefabric is acted upon by cooperating feeding and retarding rollers thatare spaced-apart a distance greater than the thickness of the fabric.Thus, opposite fabric sides cannot be in simultaneous contact with thefeeding and retarding rollers at the same point along the fabric. Fabricis transferred from the feeding roller to the retarding roller, whileopposite sides of the fabric are closely confined in a compacting zone,free of contact with either roller. Fabric is longitudinally compactedduring its traverse of that zone. In the second stage, the rollers arereversely oriented with respect to the fabric. Not more than 60% of thecompacting effort is imparted in either one of the stages. Preferably,each stage imparts about 50% of the compacting effort.

It is apparent that numerous innovations for compressively treatingfabrics have been provided in the prior art, which are adapted to beused. Furthermore, even though these innovations may be suitable for thespecific individual purposes to which they address, nevertheless, theywould not be suitable for the purposes of the embodiments of the presentinvention as heretofore described, namely, a method and apparatus forpre-shrinking a wet fabric prior to drying.

SUMMARY OF THE INVENTION

Thus, an object of the embodiments of the present invention is toprovide an apparatus and method for pre-shrinking a wet fabric prior todrying, which avoids the disadvantages of the prior art.

Passing a knit fabric in tubular or open form through mechanicalcompression or a compacting station in the “wet” state prior to drying,in order to provide lengthwise compression of the fabric, increases thestitches or courses per inch and re-orients the knit construction toreduce residual shrinkage in the finished fabric and garments.

The definition of “wet” is the amount of residual moisture present inthe fabric prior to processing, which can range from 30-300%. Theresidual moisture includes one of water and any mixture of water andprocess chemicals.

Briefly stated, another object of the embodiments of the presentinvention is to provide an apparatus and method for pre-shrinking a wetfabric prior to drying. The apparatus includes, among other components,a balloon extractor station and a hydro-sizer compression station. Theballoon extractor station removes some water from the wet fabric. Thehydro-sizer compression station is operatively connected to, anddisposed downstream of, the balloon extractor station, and compressesthe wet fabric in a lengthwise direction, and in doing so, pre-shrinksthe wet fabric prior to drying. The method includes, among other steps,extracting some water from the wet fabric so as to form ahydro-extracted and wet fabric, compressing lengthwise thehydro-extracted and wet fabric so as to form a compacted and wet fabricthat is now pre-shrunk prior to drying, and drying the compacted and wetfabric so as to form a compacted and dry fabric.

The novel features considered characteristic of the embodiments of thepresent invention are set forth in the appended claims. The embodimentsof the present invention themselves, however, both as to theirconstruction and to their method of operation together with additionalobjects and advantages thereof will be best understood from thefollowing description of the embodiments of the present invention whenread and understood in connection with the accompanying figures of thedrawing.

BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING

The figures of the drawing are briefly described as follows:

FIG. 1 is a diagrammatic side elevational view of the apparatus of theembodiments of the present invention;

FIG. 2 is a diagrammatic top plan view taken in the direction of ARROW 2in FIG. 1 of the apparatus of the embodiments of the present invention;

FIG. 3 is an enlarged diagrammatic side elevational view of the areagenerally enclosed by the dotted curve identified by ARROW 3 in FIG. 1of the twin balloon pad station, the hydro-sizer compression station,and the folding station of the apparatus of the embodiments of thepresent invention;

FIG. 4 is a diagrammatic top plan view taken generally in the directionof ARROW 4 in FIG. 3 of the twin balloon pad station, the hydro-sizercompression station, and the folding station of the apparatus of theembodiments of the present invention;

FIGS. 5A-5D are a flowchart of the method of the embodiments of thepresent invention pre-shrinking a wet fabric prior to drying; and

FIG. 6 is a tabulation of initial test results achieved by the apparatusand method of the embodiments of the present invention.

LIST OF REFERENCE NUMERALS UTILIZED IN THE FIGURES OF THE DRAWINGIntroductory

-   10 apparatus of embodiments of present invention for pre-shrinking    wet fabric 12 prior to drying-   12 wet fabric

Overall Configuration of Apparatus 10 for Pre-shrinking Wet Fabric 12Prior to Drying

-   14 balloon extractor station for removing some water 18 from wet    fabric 12-   16 hydro-sizer compression station for compressing wet fabric 12 in    lengthwise direction, and in doing so, pre-shrinks wet fabric 12    prior to drying-   18 water of wet fabric 12-   20 entry system station-   22 knit washer station-   24 twin balloon pad station for padding on one of chemical softeners    28 and lubricants 30 and for removing excess water 18 and excess of    one of chemical softeners 28 and lubricants 30 from wet fabric 12-   26 folding station-   28 chemical softeners-   30 chemical lubricants-   31 non-ionic of one of chemical softeners 28 and chemical lubricants    30-   31 a cationic of one of chemical softeners 28 and chemical    lubricants 30-   31 b polyethylene of one of chemical softeners 28 and chemical    lubricants 30-   31 c silicone of one of chemical softeners 28 and chemical    lubricants 30-   31 d soil and stain release agents of one of chemical softeners 28    and chemical lubricants 30

Specific Configuration of Entry System Station 20

-   32 48″ hydraulic turntable of entry system station 20-   34 twist sensor of entry system station 20 for automatic de-twisting-   36 driven cloth lifter of entry system station 20 for automatic    de-twisting-   38 motorized pot-eye de-twister of entry system station 20-   40 “O” ring guiders of entry system station 20-   42 powered width control of “O” ring guiders 40 of entry system    station 20-   44 hole detectors of “O” ring guiders 40 of entry system station 20

Specific Configuration of Balloon Extractor Station 14

-   46 driven feed roll of balloon extractor station 14 for drawing wet    fabric 12 through ring guides 48 of balloon extractor station 14 and    into pre-wet extracting scary 50 of balloon extractor station 14-   48 ring guides of balloon extractor station 14-   50 pre-wet extracting scary of balloon extractor station 14-   52 extracting scary of balloon extractor station 14 for automatic    speed control and air for ballooning wet fabric 12-   54 idler/dancer assembly of extracting scary 52 of balloon extractor    station 14-   56 pair of extracting squeeze rolls of balloon extractor station 14-   58 metal of each extracting squeeze roll of pair of extracting    squeeze rolls 56 of balloon extractor station 14-   60 metal core of each extracting squeeze roll of pair of extracting    squeeze rolls 56 of balloon extractor station 14-   62 polyurethane of each extracting squeeze roll of pair of    extracting squeeze rolls 56 of balloon extractor station 14-   64 rubber of each extracting squeeze roll of pair of extracting    squeeze rolls 56 of balloon extractor station 14-   66 other synthetic compounds of each extracting squeeze roll of pair    of extracting squeeze rolls 56 of balloon extractor station 14

Specific Configuration of Knit Washer Station 22

-   68 continuous washing chamber of knit washer station 22-   70 eight individual compartments of continuous washing chamber 68 of    knit washer station 22-   72 eight immersion rolls of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   74 eight carrier rolls of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   76 four nip roll assemblies of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   78 two directional rolls of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   80 displacement baffles of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   82 air injection assemblies of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   84 compartment drains of eight individual compartments 70 of    continuous washing chamber 68 of knit washer station 22-   86 overflow drains of eight individual compartments 70 of continuous    washing chamber 68 of knit washer station 22-   88 pneumatic loading of four nip roll assemblies 76 of eight    individual compartments 70 of continuous washing chamber 68 of knit    washer station 22-   90 PH system of knit washer station 22-   92 acid circulation pump of PH system 90 of knit washer station 22-   94 electronic metering pump of PH system 90 of knit washer station    22-   96 integral piping of PH system 90 of knit washer station 22-   98 PH probe of PH system 90 of knit washer station 22-   100 transmitter of PH probe 98 of PH system 90 of knit washer    station 22-   102 soap dispensing system of knit washer station 22-   104 electronic metering pump of soap dispensing system 102 of knit    washer station 22-   106 integral piping of soap dispensing system 102 of knit washer    station 22-   108 water heating system of knit washer station 22-   110 heat exchanger of water heating system 108 of knit washer    station 22 for providing 25 gallons (95 liters) per minute capacity    at 160° F. (70° C.)-   112 steam control valve of water heating system 108 of knit washer    station 22-   114 RTD of steam control valve 112 of water heating system 108 of    knit washer station 22 for water temperature measurement in    continuous washing chamber 68 of knit washer station 22-   116 temperature controller of water heating system 108 of knit    washer station 22-   118 piping of water heating system 108 of knit washer station 22-   120 fittings of water heating system 108 of knit washer station 22-   122 control valve transducer of temperature controller 116 of water    heating system 108 of knit washer station 22

Specific Configuration of Twin Balloon Pad Station 24

-   124 extracting scary of twin balloon pad station 24 for automatic    speed control and air for ballooning wet fabric 12-   126 idler/dancer assembly of extracting scary 124 of twin balloon    pad station 24-   128 pair of extracting squeeze rolls of twin balloon pad station 24-   130 chemical application pan of twin balloon pad station 24-   132 processing scary of twin balloon pad station 24 for automatic    speed control-   134 idler/dance assembly of processing scary 132 of twin balloon pad    station 24-   136 pair of padding rolls of twin balloon pad station 24-   138 solution controller of twin balloon pad station 24 for automatic    control of volume of one of chemical softeners 28 and chemical    lubricants 30-   140 after-spreaders of twin balloon pad station 24-   142 pair of spreaders of after-spreaders 140 of twin balloon pad    station 24-   144 powered width change of pair of spreaders 142 of after-spreaders    140 of twin balloon pad station 24-   146 hole detectors of pair of spreaders 142 of after-spreaders 140    of twin balloon pad station 24-   148 metal of each extracting squeeze roll of pair of extracting    squeeze rolls 128 of twin balloon pad station 24 and each padding    roll of pair of padding rolls 136 of twin balloon pad station 24-   150 metal core of each extracting squeeze roll of pair of extracting    squeeze rolls 128 of twin balloon pad station 24 and each padding    roll of pair of padding rolls 136 of twin balloon pad station 24-   152 polyurethane of each extracting squeeze roll of pair of    extracting squeeze rolls 128 of twin balloon pad station 24 and each    padding roll of pair of padding rolls 136 of twin balloon pad    station 24-   154 rubber of each extracting squeeze roll of pair of extracting    squeeze rolls 128 of twin balloon pad station 24 and each padding    roll of pair of padding rolls 136 of twin balloon pad station 24-   156 other synthetic compounds of each extracting squeeze roll of    pair of extracting squeeze rolls 128 of twin balloon pad station 24    and each padding roll of pair of padding rolls 136 of twin balloon    pad station 24

Specific Configuration of Hydro-Sizer Compression Station 16

-   158 edge-drive spreading unit of hydro-sizer compression station 16-   160 pair of spreaders of hydro-sizer compression station 16 p0 162    powered width change of pair of spreaders 160 of hydro-sizer    compression station 16-   164 hole detectors of pair of spreaders 160 of hydro-sizer    compression station 16-   166 feed roll of hydro-sizer compression station 16-   168 retard roll of hydro-sizer compression station 16-   170 shoe assembly of hydro-sizer compression station 16 for wet    compacting-   172 lower impact blade/shoe of shoe assembly 170 of hydro-sizer    compression station 16-   174 metal of each of feed roll 166 of hydro-sizer compression    station 16 and retard roll 168 of hydro-sizer compression station 16-   176 metal core of each of feed roll 166 of hydro-sizer compression    station 16 and retard roll 168 of hydro-sizer compression station 16-   178 polyurethane of each of feed roll 166 of hydro-sizer compression    station 16 and retard roll 168 of hydro-sizer compression station 16-   180 rubber of each of feed roll 166 of hydro-sizer compression    station 16 and retard roll 168 of hydro-sizer compression station 16-   182 other synthetic compounds of each of feed roll 166 of    hydro-sizer compression station 16 and retard roll 168 of    hydro-sizer compression station 16-   184 metal of lower impact blade/shoe 172 of shoe assembly 170 of    hydro-sizer compression station 16-   186 synthetic polymers of lower impact blade/shoe 172 of shoe    assembly 170 of hydro-sizer compression station 16

Specific Configuration of Folding Station 26

-   188 self-adjusting and descending rate-drop table of folding station    26 for controlling distance of travel of wet fabric 12 from top 192    of fabric transport conveyor 190 of folding station 26 to    self-adjusting and descending-rate drop table 188 of folding station    26 for preventing compaction percentage of length tension of wet    fabric 12 hanging from fabric transport conveyor 190 of folding    station 26 from being one of reduced and pulled out-   190 fabric transport conveyor of folding station 26 for delivering    wet fabric 12 to self-adjusting and descending-rate drop table 188    of folding station 26-   192 top of fabric transport conveyor 190 of folding station 26

Method 194 for Pre-Shrinking Wet Fabric 12 Prior to Drying

-   194 method for pre-shrinking wet fabric 12 prior to drying-   195 entered and wet fabric-   196 hydro-extracted and wet fabric-   198 washed, hydro-extracted, and wet fabric-   200 chemically applied, washed, hydro-extracted, and wet fabric-   202 excess chemically removed, washed, hydro-extracted, and wet    fabric-   204 compacted, washed, hydro-extracted, and wet fabric-   205 folded, compacted, washed, hydro-extracted, and wet fabric-   206 compacted and dry fabric

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Introductory

Referring now to the figures, in which like numerals indicate likeparts, and particularly to FIGS. 1 and 2, the apparatus of theembodiments of the present invention is shown generally at 10 forpre-shrinking a wet fabric 12 prior to drying.

Overall Configuration of the Apparatus 10 for Pre-shrinking the WetFabric 12 Prior to Drying

The overall configuration of the apparatus 10 for pre-shrinking the wetfabric 12 prior to drying can best be seen in FIGS. 1 and 2, and assuch, will be discussed with reference thereto.

The apparatus 10 comprises a balloon extractor station 14 and ahydro-sizer compression station 16. The balloon extractor station 14 isfor removing some water 18 from the wet fabric 12. The hydro-sizercompression station 16 is operatively connected to, and disposeddownstream of, the balloon extractor station 14, and is for compressingthe wet fabric 12 in a lengthwise direction, and in doing so,pre-shrinks the wet fabric 12 prior to drying.

The apparatus 10 further comprises an entry system station 20, a knitwasher station 22, a twin balloon pad station 24, and a folding station26.

The balloon extractor station 14 is operatively connected to, anddisposed downstream of, the entry system station 20.

The knit washer station 22 is operatively connected to, and disposeddownstream of, the balloon extractor station 14.

The twin balloon pad station 24 is operatively connected to, anddisposed downstream of, the knit washer station 22, and is for paddingon one of chemical softeners 28 and chemical lubricants 30 and forremoving excess water 18 and excess of the one of the chemical softeners28 and the chemical lubricants 30 from the wet fabric 12.

The one of the chemical softeners 28 and the chemical lubricants 30include at least one of non-ionic 31, cationic 31 a, polyethylene 31 b,silicone 31 c, and soil and stain release agents 31 d.

The hydro-sizer compression station 16 is operatively connected to, anddisposed downstream of, the twin balloon pad station 24.

Specific Configuration of the Entry System Station 20

The specific configuration of the entry system station 20 can best beseen in FIGS. 1 and 2, and as such, will be discussed with referencethereto.

The entry system station 20 includes a 48″ hydraulic turntable 32 and atwist sensor 34.

The entry system station 20 further includes a driven cloth lifter 36.The driven cloth lifter 36 of the entry system station 20 and the twistsensor 34 of the entry system station 20 are for automatic de-twisting.

The entry system station 20 further includes a motorized pot-eyede-twister 38 and “O” ring guiders 40. The “O” ring guiders 40 of theentry system station 20 have a powered width control 42 and holedetectors 44.

Specific Configuration of the Balloon Extractor Station 14

The specific configuration of the balloon extractor station 14 can bestbe seen in FIGS. 1 and 2, and as such, will be discussed with referencethereto.

The balloon extractor station 14 includes a driven feed roll 46. Thedriven feed roll 46 of the balloon extractor station 14 is for drawingthe wet fabric 12 through ring guides 48 of the balloon extractorstation 14 and into a pre-wet extracting scary 50 of the balloonextractor station 14.

The balloon extractor station 14 further includes an extracting scary52. The extracting scary 52 of the balloon extractor station 14 is forautomatic speed control and air for ballooning the wet fabric 12, andhas an idler/dancer assembly 54.

The balloon extractor station 14 further includes a pair of extractingsqueeze rolls 56.

Each extracting squeeze roll 56 of the balloon extractor station 14 ismade from one of a metal 58 and a metal core 60 covered in one of apolyurethane 62, rubber 64, and other synthetic compounds 66, and has a7″ (17.78 cm) diameter and a 38″ (96.52 cm) face.

Specific Configuration of the Knit Washer Station 22

The specific configuration of the knit washer station 22 can best beseen in FIGS. 1 and 2, and as such, will be discussed with referencethereto.

The knit washer station 22 includes a continuous washing chamber 68.

The continuous washing chamber 68 of the knit washer station 22 is madefrom stainless steel, and has eight individual compartments 70.

The eight individual compartments 70 of the continuous washing chamber68 of the knit washer station 22 include eight immersion rolls 72, eightcarrier rolls 74, four nip roll assemblies 76, two directional rolls 78,displacement baffles 80, air injection assemblies 82, compartment drains84, and overflow drains 86.

The four nip roll assemblies 76 of the eight individual compartments 70of the continuous washing chamber 68 of the knit washer station 22 havepneumatic loading 88.

The knit washer station 22 further includes a PH system 90.

The PH system 90 of the knit washer station 22 has an acid circulationpump 92, an electronic metering pump 94, integral piping 96, and a PHprobe 98.

The PH probe 98 of the PH system 90 of the knit washer station 22 has atransmitter 100. The knit washer station 22 further includes a soapdispensing system 102. The soap dispensing system 102 of the knit washerstation 22 has an electronic metering pump 104 and integral piping 106.

The knit washer station 22 further includes a water heating system 108.

The water heating system 108 of the knit washer station 22 has a heatexchanger 110. The heat exchanger 110 of the water heating system 108 ofthe knit washer station 22 is for providing 25 gallons (95 liters) perminute capacity at 160° F. (70° C.).

The water heating system 108 of the knit washer station 22 further has asteam control valve 112.

The steam control valve 112 of the water heating system 108 of the knitwasher station 22 is 1 ½″ and has an RTD 114. The RTD 114 of the steamcontrol valve 112 of the water heating system 108 of the knit washerstation 22 is for water temperature measurement in the continuouswashing chamber 68 of the knit washer station 22.

The water heating system 108 of the knit washer station 22 further has atemperature controller 116, and piping 118 and fittings 120 to connectthe steam control valve 112 of the water heating system 108 of the knitwasher station 22 to the continuous washing chamber 68 of the knitwasher station 22 with a maximum length of 10′ (3 meters).

The temperature controller 116 of the water heating system 108 of theknit washer station 22 has a control valve transducer 122.

Specific Configuration of the Twin Balloon Pad Station 24

The specific configuration of the twin balloon pad station 24 can bestbe seen in FIGS. 3 and 4, and as such, will be discussed with referencethereto.

The twin balloon pad station 24 includes an extracting scary 124. Theextracting scary 124 of the twin balloon pad station 24 is for automaticspeed control and air for ballooning the wet fabric 12.

The extracting scary 124 of the twin balloon pad station 24 has anidler/dancer assembly 126.

The twin balloon pad station 24 further includes a pair of extractingsqueeze rolls 128. Each extracting squeeze roll 128 of the twin balloonpad station 24 has a 7″ (17.78 cm) diameter and a 38″ (96.52 cm) face.

The twin balloon pad station 24 further includes a chemical applicationpan 130.

The chemical application pan 130 of the twin balloon pad station 24 ismade from stainless steel, and has air for ballooning the wet fabric 12.

The twin balloon pad station 24 further includes a processing scary 132.The processing scary 132 of the twin balloon pad station 24 is forautomatic speed control, and has an idler/dance assembly 134.

The twin balloon pad station 24 further includes a pair of padding rolls136. Each padding roll 136 of the twin balloon pad station 24 has a 7″(17.78 cm) diameter and a 38″ (96.52 cm) face.

The twin balloon pad station 24 further includes a solution controller138. The solution controller 138 of the twin balloon pad station 24 isfor automatic control of volume of the one of the chemical softeners 28and the chemical lubricants 30.

The twin balloon pad station 24 further includes after-spreaders 140.

The after-spreaders 140 of the twin balloon pad station 24 have a pairof spreaders 142.

The pair of spreaders 142 of the after-spreaders 140 of the twin balloonpad station 24 have powered width change 144 and hole detectors 146.

Each extracting squeeze roll 128 of the twin balloon pad station 24 andeach padding roll 136 of the twin balloon pad station 24 is made fromone of a metal 148 and a metal core 150 covered in one of a polyurethane152, rubber 154, and other synthetic compounds 156.

Specific Configuration of the Hydro-Sizer Compression Station 16

The specific configuration of the hydro-sizer compression station 16 canbest be seen in FIGS. 3 and 4, and as such, will be discussed withreference thereto.

The hydro-sizer compression station 16 includes an edge-drive spreadingunit 158, a pair of spreaders 160, a feed roll 166, a retard roll 168,and a shoe assembly 170. The shoe assembly 170 of the hydro-sizercompression station 16 is for wet compacting.

The hydro-sizer compression station 16 is for compressing the wet fabric12 in the lengthwise direction, and in so doing, pre-shrinks the wetfabric 12 prior to drying, through independent speed control of the feedroll 166 of the hydro-sizer compression station 16 and the retard roll168 of the hydro-sizer compression station 16.

The pair of spreaders 160 of the hydro-sizer compression station 16 havepowered width change 162 and hole detectors 164.

The shoe assembly 170 of the hydro-sizer compression station 16 has alower impact blade/shoe 172.

The lower impact blade/shoe 172 of the shoe assembly 170 of thehydro-sizer compression station 16 is made from one of metal 184 andsynthetic polymers 186.

Each of the feed roll 166 of the hydro-sizer compression station 16 andthe retard roll 168 of the hydro-sizer compression station 16 is madefrom the one of a metal 174 and a metal core 176 covered in one ofpolyurethane 178, rubber 180, and other synthetic compounds 182.

The feed roll 166 of the hydro-sizer compression station 16, the retardroll 168 of the hydro-sizer compression station 16, and the lower impactblade/shoe 172 of the shoe assembly 170 of the hydro-sizer compressionstation 16 can be heated or cooled in order to be operated at acontrolled temperature ranging from 50-400° F.

Specific Configuration of the Folding Station 26

The specific configuration of the folding station 26 can best be seen inFIGS. 3 and 4, and as such, will be discussed with reference thereto.

The folding station 26 includes a self-adjusting and descending-ratedrop table 188 and a fabric transport conveyor 190. The fabric transportconveyor 190 of the folding station 26 is for delivering the wet fabric12 to the self-adjusting and descending-rate drop table 188 of thefolding station 26, and includes a top 192.

The self-adjusting and descending rate-drop table 188 of the foldingstation 26 is for controlling distance of travel of the wet fabric 12from the top 192 of the fabric transport conveyor 190 of the foldingstation 26 to the self-adjusting and descending-rate drop table 188 ofthe folding station 26 for preventing compaction percentage of lengthtension of the wet fabric 12 hanging from the fabric transport conveyor190 of the folding station 26 from being one of reduced and pulled out.

Method 194 for Pre-Shrinking the Wet Fabric 12 Prior to Drying

The method 194 for pre-shrinking the wet fabric 12 prior to drying canbest be seen in FIGS. 5A-5D, and as such, will be discussed withreference thereto.

The method 194 for pre-shrinking the wet fabric 12 prior to dryingcomprises the steps of:

STEP 1: Entering the wet fabric 12 into the balloon extractor station 14via the entry system station 20 so as to form an entered and wet fabric195;STEP 2: Extracting some of the water 18 from the entered and wet fabric195 via the balloon extractor station 14 so as to form a hydro-extractedand wet fabric 196;STEP 3: Washing the hydro-extracted and wet fabric 196 via the knitwasher station 22 so as to form a washed, hydro-extracted, and wetfabric 198;STEP 4: Applying one of the chemical softeners 28 and the chemicallubricants 30 to the washed, hydro-extracted, and wet fabric 198 via thetwin balloon pad station 24 so as to form a chemically applied, washed,hydro-extracted, and wet fabric 200;STEP 5: Removing excess of the one of the chemical softeners 28 and thechemical lubricants 30 from the chemically applied, washed,hydro-extracted, and wet fabric 200 via the twin balloon pad station 24so as to form an excess chemically removed, washed, hydro-extracted, andwet fabric 202;STEP 6: Compressing lengthwise the excess chemically removed, washed,hydro-extracted, and wet fabric 202 via the hydro-sizer compressionstation 16 so as to form a compacted, washed, hydro-extracted, and wetfabric 204 that is now pre-shrunk prior to drying;STEP 7: Folding the compacted, washed, hydro-extracted, and wet fabric204 via the folding station 26 so as to form a folded, compacted,washed, hydro-extracted, and wet fabric 205; andSTEP 8: Drying the folded, compacted, washed, hydro-extracted, and wetfabric 205 so as to form a compacted and dry fabric 206.

Empirical Data

On a typical 100% cotton jersey knit construction with 30/1 S yarn, thecourses per inch (CPI) or stitches per inch vary from 44-47 afterextraction and chemical application. Compacting the fabric in the “wet”state after the extraction and chemical process between 10-25% increasesthe CPI to 50-52 CPI.

Drying allows for further shrinkage occurrences, and the final drycompacting process only needs to add 1-2 CPI or 5-10% compaction to thefabric. With a standard finished CPI of 52, an end result of 52-54 CPIis possible. This allows for actual growth in the lengthwise directioninstead of shrinkage.

The amount of compaction or compression in the lengthwise direction isadjustable allowing targeting a specific CPI. Previous methods of drycompacting will not afford these same low shrinkage or growthconditions.

Please see FIG. 6 for a tabulation of initial test results achieved bythe method and apparatus of the embodiments of the present invention.

Advantages of the Method 194 and the Apparatus 10 For Pre-shrinking theWet Fabric 12 Prior to Drying

-   -   The compression of the fabric in the lengthwise direction in the        wet state reduces the amount of lengthwise compression required        in the final dry compacting stage of the finished fabric. This        reduces the likelihood that top-to-bottom shine or shade change        or overall shine and/or shade change or shade loss occurs;    -   The continual process avoids dye migration that would render the        fabric with major quality defects, such as, lengthwise        compression of the fabric, as the extraction-chemical        application-compacting process is continual;    -   The compaction of the fabric in the lengthwise direction in the        wet state prior to drying imparts lower residual shrinkage after        drying. This reduces the compaction requirement of the fabric in        the lengthwise direction in the final finishing process, and        thus, increases and improves the stability of the finished        fabric during cutting and sewing;    -   The compaction of the fabric in the lengthwise direction in the        wet state prior to drying achieves the final finished fabric        requirements and eliminates a need for a final compacting or        finishing process in certain cases. This fabric could pass        directly from the drying process to the cutting and sewing        process; and    -   The compaction of the fabric in the lengthwise direction in the        wet state reduces the number of yards in the lot in process, and        thus, increases the productive efficiency of the dryer as there        are less yards in process.

Impressions

It will be understood that each of the elements described above or twoor more together may also find a useful application in other types ofconstructions differing from the types described above.

While the embodiments of the present invention have been illustrated anddescribed as embodied in a method and apparatus for pre-shrinking a wetfabric prior to drying, nevertheless, they are not limited to thedetails shown, since it will be understood that various omissions,modifications, substitutions, and changes in the forms and details ofthe embodiments of the present invention illustrated and their operationcan be made by those skilled in the art without departing in any wayfrom the spirit of the embodiments of the present invention.

Without further analysis, the foregoing will so fully reveal the gist ofthe embodiments of the present invention that others can by applyingcurrent knowledge readily adapt them for various applications withoutomitting features that from the standpoint of prior art fairlyconstitute characteristics of the generic or specific aspects of theembodiments of the present invention.

The invention claimed is:
 1. A method for pre-shrinking a wet fabricprior to drying, comprising the steps of: a) entering the wet fabricinto a balloon extractor station via an entry system station so as toform an entered and wet fabric; b) extracting some water from the wetfabric via a balloon extractor station so as to form a hydro-extractedand wet fabric; c) washing the hydro-extracted and wet fabric via a knitwasher station so as to form a washed, hydro-extracted, and wet fabric;d) applying one of chemical softeners and chemical lubricants to thewashed, hydro-extracted, and wet fabric via a twin balloon pad stationso as to form a chemically applied, washed, hydro-extracted, and wetfabric; e) removing excess of the one of the chemical softeners and thechemical lubricants from the chemically applied, washed,hydro-extracted, and wet fabric via the twin balloon pad station so asto form an excess chemically removed, washed, hydro-extracted, and wetfabric; f) compressing lengthwise the excess chemically removed, washed,hydro-extracted, and wet fabric via a hydro-sizer compression station soas to form a compacted, hydro-extracted, and wet fabric that is nowpre-shrunk prior to drying; g) drying the compacted, hydro-extracted,and wet fabric so as to form a compacted and dry fabric; and h) foldingthe compacted and dry fabric via a folding station so as to form afolded, compacted, and dry fabric.